To replace the output shaft of the BWD22 - 29 - 4KW cycloidal pinwheel reducer, you need to follow the core process of 'disassembly - cleaning and inspection - assembly - trial operation'. During the operation, the components must be marked to avoid assembly misalignment and to protect precision components from damage. The specific steps are as follows:
1. Preparation before replacement
1. Safety and site preparation : First disconnect the power supply of the reducer and hang a warning sign to prevent accidental startup. Clean the working area and lay down protective mats to prevent parts from being bumped or contaminated with impurities; wear anti-cut gloves and goggles to ensure safe operations.
2. Preparation of tools and materials : Prepare hex wrenches, torque wrenches, three-claw pullers, copper rods, markers, cleaning cloths and other tools; prepare a new output shaft of the same model, as well as supporting seals, fastening rings, grease, sealant and other consumables, and prepare kerosene or gasoline for cleaning parts.
2. Disassemble the old output shaft
1. Oil drain and mark : Unscrew the oil drain bolt and drain the internal lubricating oil of the reducer. Use a marker pen to mark assembly marks on the machine base, pin tooth shell, and end cover respectively, and record the relative position and assembly sequence of each component to avoid subsequent assembly errors.
2. Separate external connections : Remove the connecting bolts between the reducer and the motor and load equipment, separate the coupling or flange, and place the reducer independently; if there is a fan cover and fan blades at the input end, use a puller to remove them.
3. Disassemble the machine body : Loosen the connecting bolts between the machine base and the pin tooth shell in diagonal order, and use a nylon crowbar to slowly separate the two parts from the joint surface. Do not use brute force to damage the sealing surface. Then gradually remove the pin sleeve and spring retaining ring for the shaft, and then remove the bearing retaining ring of the shaft head.
4. Take out the internal related components : Hold the rolling bearing on the eccentric sleeve with both hands, and remove the eccentric sleeve along the axial direction; then take out the cycloid wheel assembly according to the mark (note the direction of the cycloidal wheel phase mark), then remove the hole spring retaining ring and remove the input shaft to make room for the output shaft disassembly.
5. Disassemble the old output shaft : Pad the machine base with hard rubber or sleepers, put a copper rod on the end of the output shaft, gently hammer the copper rod along the axial direction, separate the old output shaft with rolling bearing from the machine base, and take out the old shaft and supporting fastening rings, oil seals and other components.
3. Cleaning and parts inspection
1. Use kerosene or gasoline to thoroughly clean the machine base, pin gear housing, cycloidal wheel, eccentric sleeve and other disassembled parts to remove oil stains, iron filings and wear dust, especially impurities in the output shaft mounting hole.
2. Check whether the cycloidal wheel, pin tooth pin, and pin tooth sleeve are worn and deformed, whether the bearings are stuck or abnormally loud, and whether the seals are aged and damaged. If damaged, they need to be replaced simultaneously to avoid premature wear of the new output shaft due to failure of related components.
3. Check the size, shaft diameter and keyway specifications of the new output shaft to ensure that they are consistent with the old shaft and that there are no bumps, burrs or other defects on the shaft surface.
4. Assemble the new output shaft
1. First apply grease to the bearing installation position of the new output shaft, and install the matching bearing on the new shaft. During installation, you can gently tap the outer ring of the bearing with a copper rod to assist in positioning. It is prohibited to hammer the bearing bracket.
2. Flatten the machine base, align the new output shaft with the bearings installed in the machine base mounting hole, tap the recessed part of the output shaft with a copper rod, and install it into the machine base. Pay attention to ensure the coaxiality of the output shaft and the machine base hole. Do not directly hammer the key working surface of the shaft.
3. Install the fastening ring and assemble the cycloidal wheel components in sequence according to the original marked positions to ensure that the phase of the cycloid wheel is correct. Then install the eccentric sleeve, rolling bearing and other components back to their original positions. When installing the pin, pay attention to fixing the position of the spacer ring to prevent the spacer ring from being crushed.
4. Install a new oil seal, apply grease to the lip of the oil seal, and adjust the tightness of the oil seal spring; then close the pin tooth housing and the machine base, tighten the connecting bolts evenly in diagonal order, and apply sealant to the joint surface to prevent oil leakage.
5. Closing and trial operation
1. Inject appropriate lubricating oil into the reducer. The amount of oil must comply with the specified scale of the equipment, not too much or too little.
2. Turn the input shaft by hand and check whether the shaft system rotates smoothly and there is no jamming, friction or abnormal noise.
3. Turn on the power and perform idling test operation. During operation, observe whether the equipment has any vibration or abnormal noise, and check whether there is lubricating oil leakage at the output shaft. After the idling is normal, connect the load equipment for a test run with load, monitor whether the output torque and speed meet the requirements, and complete the replacement after confirming that there is no fault.
